Tubular tapered connectors



Feb. 8, 1966 M. c LOGAN ETAL 3,

TUBULAR TAPERED CONNECTORS Filed March 14, 1963 5 Sheets-Sheet l FIG.I

INVENTORS M. C. LOGAN J. CRIMMINS ATTORNEY Feb. 8, 1966 M. c. LOGAN ETAL3,234,321

TUBULAR TAPERED CONNECTORS Filed March 14, 1963 5 Sheets-Sheet 2INVENTORS LO G A N CRIM MINS ATTORNEY Feb. 8, 1966 M. c. LOGAN ETAL3,234,321

TUBULAR TAPERED CONNECTORS 5 Sheets-Sheet 5 Filed March 14, 1963INVENTORS M. C. LOGA N D. J. CRIMMINS ATTORNEY United States PatentOfiFice 3,234,321 Patented Feb. 8, 1966 3,234,321 TUBULAR TAPEREDCONNECTORS Maurus C. Logan, Elizabeth, and David .1. Crimmins, Nutley,N..I., assignors to The Thomas & Bette 60., a corporation of New ierseyFiled Mar. 14, 1963, Ser. No. 265,203 4 Claims. (Cl. 174-75) Thisinvention relates to a connector to be formed on the bared end extendingfrom an electrical conductor so as to define the tapered connector endthereto, to facilitate electrical connection of the conductor to anothercondoctor or electrical element.

Pursuant to the invention, the connector is essentially electrically andphysically homogeneously united with the bared end of an electricalconductor wire encompassed therein, providing a connector of novelconstruction such that repeated use thereof may be made without damage,distortion, power loss or failure. The connector is further well adaptedfor use in many applications wherein limited space is available thereforand is highly durable and reliable in use.

The connector is formed from a flat blank into a tapered portion whichis (at least partially) essentially solid in cross section with the barewire end on which it is assembled.

Further pursuant to the invention, the connector is formed from a blankprovided with longitudinal edges transversely complementarily formed forinterfitting on closing the blank, thus resisting and preventing axialdistortion of the connector in use.

The drawings, illustrating procedures and devices useful in carrying outthe invention, and the description below, are exemplary only of theinvention, which shall be deemed to cover all other devices andprocedures coming within the scope and purview of the appended claims.

In the drawings, wherein similar reference characters indicate likeparts:

FIG. 1 is a partly fragmentary, plan view of a connector embodying theinvention,

FIG. 2 is a similar view of another form thereof,

FIG. 3 is a vertical, longitudinal, sectional view thereof, taken atline 3-3 of FIG 1,

FIG. 4 is a fragmentary, top plan view of another form of connectorembodying the invention,

FIG. 5 is a fragmentary partly sectional view taken at line 5-5 of FIG.7, of a connector member of this invention, engaging a complementarilyformed member 28,

FIG. 6 is an enlarged, fragmentary, vertical sectional 0 view, showingsuch connector inserted into a conductormember by an applying tool, andfurther showing a second connector, embodying the invention, about to beso inserted,

FIG. 7 is a fragmentary, plan view of a member 28 to which a pluralityof conductors are shown secured,

FIG. 8 is a fragmentary, sectional view of a conductor member, showing aconnector of this invention being inserted therein,

FIG. 9 is a partly fragmentary, perspective view of a continuous stripforming procedure which may be used in the manufacture of the connectorof this invention, and

FIG. 10 is a transverse, sectional view of a connector formed with thetab 36 (FIG. 9) extending substantially from a longitudinal edge withthe tab folded inwardly of the connector,

FIG. 11 is a plan view of a blank used in the forming of the connectorof the present invention.

As shown in the drawings, the connector 10 (FIG. 1) of this invention isformed from a pre-cut elongated blank 11 (FIGS. 9 and 11) preferably ofmetal, alloy or other materials which may be coated or plated if desiredand which may be self conducting or may be formed, plated or coated witha conducting material to render the same conductive or to improve theconductivity thereof. The blank has opposite longitudinal edges 12, 13(FIGS. 1, 4, 9, 11) so formed (as below described) that, when the blankis closed, it will define a tapered, longitudinal tubular form, asindicated at 14 in FIG. 9 and the longitudinal edges 12 and 13 willinterfit and be disposed contiguously. The blank is formed (FIGS. 1 and11) with a major portion 15 thereof having the longitudinal edgesthereof so contoured to define, when the blank is rolled or otherwiseformed to closed position, an elongated tapered end; the remaining,short end portion 16 (FIGS. 9 and 11) forms, on closing the blank, aring portion 17 which may have a slot 18 therein for (FIG. 6) inspectionand checking purposes. The connector is designed for application to thebared wire end 19 (FIG. 3) extending through and projecting from end 20of a sheath or length of insulated conductor wire or cable 21. The baredend 19 may be single wire strand or a plurality of strands or cable asshown. The bare end 19 is wedged and gathered tightly in the so-formedtapered end of the blank in the closing operation as shown in FIG.

' 3 and the conductor may be crimped at at least the ring end 17 of theblank if desired.

The bared wire end 19 is positioned initially on the major end 15 of theblank (center blank, FIG. 9) with the end 20 of the insulation sheath 21positioned on the ring portion 17 of the blank and then the blank isfolded or formed over the bared wire end 19 as by rolling the blank totubular tapered form 14 (FIG. 8) to close the blank tightly over saidbared wire end 19, the ring 17 gripping the end 213 of the insulatedconductor length 21.

Thus, the wire end 19 and the tapered portion 14 of the connector areessentially homogeneously electrically united, so that current will flowessentially directly from the wire end 19 to the other conductor memberof the block 23 into which the end 15 is inserted, without anyappreciable power loss or electrical resistance. When the blank is soformed to final tubular tapered form, the end 16 (FIG. 9) is, as abovenoted, formed as an encircling ring 1'7 over the end 20 of the wireenclosing insulating sheath 21.

While any forming operation may be followed in carrying out theinvention, a convenient procedure is illustrated in FIG. 9, wherein theblanks 11 are shown initially connected to an elongated feed strip 25 bythe severable tabs 26, as by initially blanking a fiat sheet of metal tothat form; concurrently with the forming of the connector to thelongitudinal tubular form 14 or immediately thereafter, the tab 26 maybe severed, disconnecting the blank at tab 26 from the elongated feedstrip 25. In this procedure, the blank may be initially partially formedto generally channeled longitudinal configuration to facilitatepositioning the bared wire end 19 and the insulating sheath 2t) thereon,preparatory to the step of forming blank to its longitudinal tubularform 14 and severing the same from the feed strip 25.

In further re-enf orceinent of the connector, to enable repeated usethereof without distortion, and greatly enhancing the etlicacy andreliability thereof in use, the marginal longitudinal edges 12, 12 ofthe major portion 15 of the connector may be provided with complementarytransversely sinuous or transversely disposed interfitting portionswhich may be formed as alternate outwardly and inwardly extending curvedportions 31, 32, 33 (FIG. 1, 39, 46, FIG. 2) thereof disposed generallytransversely of the longitudinal axis of the major portion 15 of theconnector and thus interfitting in the final formation thereof toenhance the closure action of the blank on the wire end and toefifectively counter and resist stresses and strains and preserve thetapered tubular form and accurate functioning of the connector. FIG. 4shows a single outwardly extending rectangular portion 34 extendingbeyond one of the longitudinal edges of the major portion 15 of theconnector and received in a complementarily formed recess 35 in theother longitudinal edge thereof, and FIG. 2 shows a tapered outwardlyextending portion 39 received in a complementarily formed recess'40. 7

As shown in FIG. 9, the elongated fingers 36, 37, may be formed toextend from one or both longitudinal edges of the blank to lessen thediameter of the blank, so that when the blank is folded and formed (asshown in FIGS. 9, 1-5) and said fingers are folded inwardly of the blank(FIG. 10), it will hold a bare wire end of such lesser diameter.

The blanks may be so formed with such fingers alternately in the seriesof blanks (as in FIG. 9) to adapt those (so formed) blanks to use withbare wire ends of substantially lesser diameters than those with whichthe blanks are customarily used. The blanks may be formed uniformly withsuch fingers when it is desired to have all blanks adaptable to suchfurther use. The fingers may be weakened as noted at 38, 38 (FIG. 9) sothat the fingers may be broken ofi where, after they are so formed,

it is not desired to use them, The blank may be further provided at thejuncture of the major and minor portions (15 and 16).thereof, with atransversely formed continuous projection 27 (FIG. '1). When the blankis formed to final tubular form, the connector may be positioned in anydesired block member 28, which may be provided with tapered engagingconductor means such as 29 (FIG. the parts being complementarily formedso that the connector may be driven into frictional engagement therewithby any suitable tool, such as indicated at 30 in FIG. 8. The toolpresses against the transversely formed projection 27 tothat end anddrives the connector into frictional engagement with the tapered means29. The latter may connect the members 10 with others (FIG. 6) or withother components or equipment according to the end use desired. It willbe noted that longitudinal axial length of the ring portion 17 is veryshort, thus substantially reducing the length available for applyingright angle tilting or damaging leverage and reducing the likelihood ofdam-age to the pin which usually occurs at the point of juncture of thering and tapered portions, or to the pin and socket joint itself. Aswill be noted from FIG. 7 the construction of this inventionadditionally enables the utilization of such connectors in manyapplications wherein the space available between adjacent pieces ofequipment 30 is extremely limited,

It will be noted from FIG. 3 that the bared wire end 19 of the conductorwire is, in the connector of this invention, directly aligned with themajor tapered end portion thereof and is in direct physically compressedengagement therewith so that, upon insertion of the connector into theconductor members 28, current will flow in an essentially straight line,from the bared wire 19 to the conductor member 28, reducing to anessential minimum any possibility of power loss and providing a positiveand constant direct electrical connection. Although the blank of whichthe connector is formed is of relatively small cross-sectionaldimensions, the tapered tubular form 14 of the finished connector thusformed defines an essentially rigid, solid cross section continuous withthe contained, bared wire end 19 at the point of electrical connection.

Having thus described our invention, what we claim as new and desire tosecure by Letters Patent are:

1.. In a one-piece blank formable'into a terminal con nector for aninsulated electrical conductor cable, the combination comprising, anelongated flat blank including opposed complementary longitudinal edges,said complementary edges including transversely disposed interfittingmeans registrable when said blank is formed into a connector, each ofsaid longitudinal edges diverging with respect to the other to define amajor tapered portion terminating at one end of said blank when theblank is formed into a connector, a conductor receiving socket withinsaid major tapered portion, means defining a substantially cylindricalminor ring portion integral with said tapered portion and extendingtherefrom at the end opposite said tapered hollow portion to receive aninsulated covered portion of said conductor when said blank is formedinto a connector, and finger means formed on at least one longitudinaledge of said blank and extending outwardly therefrom, said fingerselectively foldable with respect to said edge to a position within saidtapered hollow portion when said blank is formed into a connector todecrease the interior diameter of said hollow tapered portion toaccommodate conductors of reduced diameter.

2. The one-piece blank formable into an electrical connector defined byclaim 1, wherein said blank includes means defining a transverselydisposed projection at the juncture of said major and minor portionsthereof when said blank is formed into a connector.

3. The one-piece blank formable into an electrical connector defined byclaim 1, wherein said finger means are formed on both longitudinal edgesof said blank to extend outwardly therefrom.

4. The one-piece blank forrnable into an electrical connector defined byclaim 1, wherein said interfitting means include at least one outwardlyextending and at least one complementary inwardly extending sinuousportion, V I

References Cited by the Examiner UNITED STATES PATENT S 871,535 11/1907Thatcher 339223 962,921 6/1910 Schneider 339223 1,788,354 1/193'1 Alden339 223 2,811,702 10/ 1957 Narozny 29-193 X 2,877,441 3/1959 'Narozny339--217 X 2,996,794 4/1961 Burdick 29--193 3,005,180 10/1961 Dreher339210 3,051,773 8/1962 Batcheller 339-276 X 5,077,027 2/1963 'Sola etal 339223 X FOREIGN PATENTS 912,466 4/ 1954 Germany. 7

' OTHER REFERENCES Aircraft-Marine Products (Italian), 536, 802, Dec.12, 1955.

ROBERT K. SCHAEFER, Primary Examiner.

JOHN. P. WILDMAN, E. JAMES SAX, JOHN F. BURNS, WILLIAM B. FREDRICKS,Assistan Examiners.

1. IN A ONE-PIECE BLANK FORMABLE INTO A TERMINAL CONNECTOR FOR ANINSULATED ELECTRICAL CONDUCTOR CABLE, THE COMBINATION COMPRISING, ANELONGATED FLAT BLANK INCLUDING OPPOSED COMPLEMENTARY LONGITUDINAL EDGES,SAID COMPLEMENTARY EDGES INCLUDING TRANSVERSELY DISPOSED INTERFITTINGMEANS REGISTRABLE WHEN SAID BLANK IS FORMED INTO A CONNECTOR, EACH OFSAID LONGITUDINAL EDGES DIVERGING WITH RESPECT TO THE OTHER TO DEFINE AMAJOR TAPERED PORTION TERMINATING AT ONE END OF SAID BLANK WHEN THEBLANK IS FORMED INTO A CONNECTOR, A CONDUCTOR RECEIVING SOCKET WITHINSAID MAJOR TAPERED PORTION, MEANS DEFINING A SUBSTANTIALLY CYLINDRICALMINOR RING PORTION INTEGRAL WITH SAID TAPERED PORTION AND EXTENDINGTHEREFROM AT THE END OPPOSITE SAID TAPERED HOLLOW PORTION TO RECEIVE ANINSULATED COVERED PORTION OF SAID CONDUCTOR WHEN SAID BLANK IS FORMEDINTO A CONNECTOR, AND FINGER MEANS FORMED ON AT LEAST ONE LONGITUDINALEDGE OF SAID BLANK AND EXTENDING OUTWARDLY THEREFROM, SAID FINGERSELECTIVELY FOLDABLE WITH RESPECT TO SAID EDGE TO A POSITION WITHIN SAIDTAPERED HOLLOW PORTION WHEN SAID BLANK IS FORMED INTO A CONNECTOR TODECREASE THE INTERIOR DIAMETER OF SAID HOLLOW TAPERED PORTION TOACCOMMODATE CONDUCTORS OF REDUCED DIAMETER.